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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

RIFTA: A Robust Iterative Fourier Transform-based dwell time Algorithm for ultra-precision ion beam figuring of synchrotron mirrors

With the rapid evolution of synchrotron X-ray sources, the demand for high-precision X-ray mirrors has greatly increased. Single nanometer profile error is required to keep imaging capability at the diffraction limit. Ion Beam Figuring (IBF), as a highly deterministic surfacing technique, has been used for ultra-precision finishing of mirrors. One crucial step that guides the IBF process is dwell time calculation. A valid dwell time solution should be non-negative and duplicate the shape of the desired removal map. Another important aspect is to minimize the total dwell time. In this study, we propose a Robust Iterative Fourier Transform-based dwell time Algorithm (RIFTA) that automatically fulfills these requirements. First, the thresholded inverse filtering in Fourier transform-based deconvolution is stabilized and automated by optimizing the threshold value using the Nelder-Mead simplex algorithm. Second, a novel two-level iterative scheme is proposed to guarantee the minimized total dwell time with its non-negativity at each dwell point. Third, a bicubic resampling is employed to flexibly adapt the calculated dwell time map to any IBF process intervals. The performance of RIFTA is first studied with simulation, followed by a comparison with the other state-of-the-art dwell time algorithms. We then demonstrate with an experiment that, using the dwell time calculated by the RIFTA, the total dwell time is shortened by a factor of two and the RMS in a 5 × 50 mm clear aperture was reduced from 3.4 nm to 1.1 nm after one IBF run, which proves the effectiveness and the efficiency of the proposed algorithm.

42 ENGINEERING↗
DOE OSTI2021

Universal dwell time optimization for deterministic optics fabrication

Computer-Controlled Optical Surfacing (CCOS) has been greatly developed and widely used for precision optical fabrication in the past three decades. It relies on robust dwell time solutions to determine how long the polishing tools must dwell at certain points over the surfaces to achieve the expected forms. However, as dwell time calculations are modeled as ill-posed deconvolution, it is always non-trivial to reach a reliable solution that 1) is non-negative, since CCOS systems are not capable of adding materials, 2) minimizes the residual in the clear aperture 3) minimizes the total dwell time to guarantee the stability and efficiency of CCOS processes, 4) can be flexibly adapted to different tool paths, 5) the parameter tuning of the algorithm is simple, and 6) the computational cost is reasonable. In this study, we propose a novel Universal Dwell time Optimization (UDO) model that universally satisfies these criteria. First, the matrix-based discretization of the convolutional polishing model is employed so that dwell time can be flexibly calculated for arbitrary dwell points. Second, UDO simplifies the inverse deconvolution as a forward scalar optimization for the first time, which drastically increases the solution stability and the computational efficiency. Finally, the dwell time solution is improved by a robust iterative refinement and a total dwell time reduction scheme. The superiority and general applicability of the proposed algorithm are verified on the simulations of different CCOS processes. A real application of UDO in improving a synchrotron X-ray mirror using Ion Beam Figuring (IBF) is then demonstrated. The simulation indicates that the estimated residual in the 92.3 mm × 15.7 mm CA can be reduced from 6.32 nm Root Mean Square (RMS) to 0.20 nm RMS in 3.37 min. After one IBF process, the measured residual in the CA converges to 0.19 nm RMS, which coincides with the simulation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A comprehensive review of dwell time optimization methods in computer-controlled optical surfacing

Dwell time plays a vital role in determining the accuracy and convergence of the computer-controlled optical surfacing process. However, optimizing dwell time presents a challenge due to its ill-posed nature, resulting in non-unique solutions. To address this issue, several well-known methods have emerged, including the iterative, Bayesian, Fourier transform, and matrix-form methods. Despite their independent development, these methods share common objectives, such as minimizing residual errors, ensuring dwell time's positivity and smoothness, minimizing total processing time, and enabling flexible dwell positions. This paper aims to comprehensively review the existing dwell time optimization methods, explore their interrelationships, provide insights for their effective implementations, evaluate their performances, and ultimately propose a unified dwell time optimization methodology.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Radioactive Thoron 220 Rn Exhalation From Unfired Mud Building Material Into Room Air of Earthen Dwellings

Thoron ( 220 Rn), an isotope of radon with a strong α-decay energy, and its short-lived metallic progeny can pose an elevated lung cancer hazard in room air when unfired-soil derived building materials are used in earthen dwellings. Changes in moisture content and density influencing the thoron exhalation rate from earthen materials into room air were studied in the laboratory with terra rossa from a village on the Ðòng Van Karst Plateau Geopark, Viêt Nam, where ethnic minorities construct traditional dwellings with unfired terra rossa walls and floors. Our results show that the thoron exhalation rate from mud surfaces depends on (i) the content of radioactive parental nuclides in mineral components; (ii) the moisture content of mud where ~5–10 weight % water maximizes the 220 Rn exhalation rate; and (iii) the density of dry mud as primarily controlled by internal macroscopic voids, fractures, and porosity. Additional time-series of 220 Rn exhalation data from an interior mud wall of a terra rossa-built house under different seasonal and weather conditions show that the temperature is influencing thoron exhalation via the water vapor pressure deficit (VPD) in air and the associated amount of atmospheric moisture adsorbed onto indoor mud surfaces. Our data suggest that occupants of “mud house” earthen dwellings in northern Viêt Nam are exposed to an increased thoron geohazard during cooler weather, low VPD, and high relative humidity in air. Detailed studies are needed to evaluate the thoron geohazard for inhabitants of mud-built dwellings in other climates and geological terrains.

58 GEOSCIENCES↗
DOE OSTI2025

CUDO: closed-form universal dwell-time optimization for computer-controlled optical surfacing

Precision optical figuring demands fast and accurate dwell time optimization to reach nanometer- and sub-nanometer-level accuracy in next-generation optical systems. We introduce CUDO (closed-form universal dwell-time optimization), the first, to the best of our knowledge, unified closed-form analytical framework that supports both function-form and matrix-form dwell time models in computer-controlled optical surfacing (CCOS). In contrast to traditional methods, which rely on iterative optimization and hyperparameter tuning, our framework derives direct analytical solutions with no adjustable parameters. This approach unifies the solution principles of existing methods within a single mathematical model, delivering three key advantages: (1) accuracy on par with, or superior to, iterative solvers, (2) substantial reduction in computation time, and (3) numerical robustness. Comparative studies with prior art confirm that closed-form solutions achieve equivalent residual error while removing runtime bottlenecks. By simplifying the implementation and enabling real-time, scalable deployment, CUDO establishes a practical foundation for future deterministic fabrication of large-aperture and high-performance optics.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Estimating the electric vehicle charging demand of multi-unit dwelling residents in the United States

Abstract Early battery electric vehicle (EV) adopters can access home chargers for reliable charging. As the EV market grows, residents of multi-unit dwellings (MUDs) may face barriers in owning EVs and charging them without garage or parking availability. To investigate the mechanisms that can bridge existing disparities in home charging and station deployment, we characterized the travel behavior of MUD residents and estimated their EV residential charging demand. This study classifies the travel patterns of MUD residents by fusing trip diary data from the National Household Travel Survey and housing features from the American Housing Survey. A hierarchical agglomerative clustering method was used to cluster apartment complex residents’ travel profiles, considering attributes such as dwell time, daily vehicle miles traveled (VMT), income, and their residences’ US census division. We propose a charging decision model to determine the charging station placement demand in MUDs and the charging energy volume expected to be consumed, assuming that MUD drivers universally operate EVs in urban communities. Numerical experiments were conducted to gain insight into the charging demand of MUD residents in the US. We found that charging availability is indispensable for households that set out to meet 80% state of charge by the end of the day. When maintaining a 20% comfortable state of charge the entire day, the higher the VMT are, the greater the share of charging demand and the greater the energy use in MUD chargers. The upper-income group requires a greater share of MUD charging and greater daily kWh charged because of more VMT.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Multi-Unit Dwelling Plug-in EV Charging Innovation Pilots (Final Report)

Nearly one-third of residences in the U.S. are multi-unit dwellings (MUDs), e.g., apartments and condominiums, and MUDs with five or more units account for approximately 45% of rental households. While 80% of EV charging takes place at home, less than 5% of home charging takes place at MUDs. With public electric vehicle (EV) charging still underdeveloped, lack of access to reliable home charging is a major barrier to EV adoption for MUD residents. Challenges to siting electric vehicle supply equipment (EVSE) at MUDs include the high upfront cost of EVSE installation, physical and/or electrical infrastructure constraints, a lack of clear incentives for property managers to invest in installing EV charging for tenants, and a limited number of EV charging service providers that offer solutions adapted to the unique needs of MUDs. Through award DE-EE0008473 from the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE), Center for Sustainable Energy (CSE), Energetics, and Forth, along with a diverse team of partners, led a three-year project to address barriers to EV charging at MUDs by developing an online toolkit geared toward residents, homeowner associations (HOAs), and property managers. The project, referred to as Vehicle Charging Innovations – Multi-Unit Dwellings (VCI-MUD project), engaged stakeholders across the country to identify real and perceived barriers to EV charging at MUDs and explored innovative technologies that attempt to alleviate the identified barriers. Over the course of three and a half years, the project conducted 60 interviews with industry stakeholders, compiled findings in an easy-to-use toolkit, and disseminated the toolkit across national, regional, state, and local channels. Key findings and outcomes of the VCI-MUD project include: Identifying six primary barriers to the installation of EV charging at MUDs; Developing five fact sheets and eight case studies highlighting innovative charging solutions to address barriers, including real-world operational and financial data; Developing a user-friendly, online empowerment toolkit with five important points for “making your pitch” to support EV charging to assist residents, property managers, building managers, and HOAs explore options for MUD charging. The VCI-MUD online toolkit was designed with replicability in mind. It includes general tools and guides to evaluate EV charging demand, gauge readiness for EV charging installation, and develop actionable plans. The fact sheets and case studies highlight the diversity of emerging MUD EV charging solutions, featuring different geographic and structural installation scenarios and providing interested parties with a menu of options, rather than prescribing a one-size-fits-all solution. The following resources are included in the toolkit to provide MUD stakeholders with all the information needed to navigate EV charging installation at their MUD location: Empowerment Toolkit – Easy-to-read FAQ overview, stakeholder roles and responsibilities, and additional resources for MUD EV charging installations; Charging Basics – Glossary of terms and descriptions of charging features, installation and operating expenses; EV Charging Survey Templates – Resident-to-Resident, Property Manager-to-Resident and HOA-to-Resident template letters with pre-populated template questions; Technology Selection Tool – Charging barrier fact sheets and case study examples; Installation Checklist – Submittal document requirements for EVSE installations; MUD Building Self-Evaluation Survey – Self-guided evaluation of potential barriers to EV charging installation at MUD locations; Curbside Resources – Case studies and fact sheets for curbside charging options; Find a Certified Electrician – Approved list of certified EV charging installers; “Right-to-Charge” State Legal References – Legal requirements for charging equipment at MUD locations. The online toolkit was promoted extensively in the final six months of the project and will continue to be disseminated by the Clean Cities Coalitions and other partners after the end of the VCI-MUD project to encourage, support, and demonstrate viable solutions for vehicle charging infrastructure in MUDs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Soil properties and biochemical composition of ground-dwelling bee nests in agricultural settings

Soils deliver underrecognized ecosystem services by supplying habitat for ground-dwelling pollinators, such as wild bees and other organisms, that pollinate 80% of insect-pollinated plants and play a critical role in securing resilient pollination provisions. Our objective is to identify soil properties of ground nesting bee nests in agricultural settings of western Oregon, USA. We confirmed ground nesting bee and sand wasp activity in 7 agricultural sites and 1 recreational park. Soils from 17 bee and sand wasp nests were analyzed for pH, particle size distribution, and carbon and nitrogen content. We visually confirmed that 8 of the nesting bees were sweat bees from the Halictidae family and identified a captured bee specimen as Lasioglossum (Dialictus) (Hymenoptera: Halictidae). We located 2 sites with sand wasps where specimens were identified as Cerceris and Bembix (Hymenoptera: Crabronidae). The organic matter composition of three soil samples scraped from the linings of active nests were assessed using Fourier transform ion cyclotron resonance mass spectrometry (FTICR-MS). The FTICR-MS results identified unknown lipid compounds in the nest soil samples, which we hypothesize are waterproofing lipids secreted to line cell walls. Bee nests occurred in slightly acidic, bare-ground soils with low rock/vegetation coverage, low organic carbon content (<1%), and exhibited significantly higher silt-plus-clay fractions (>75%) versus data published for bee nests in prior work. Our findings present important implications for textural controls on nest site selection in wet, cool environments and demonstrate the importance of integrating soil properties to improve our understanding of ground-dwelling organisms and associated soil habitats.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

The impact of habitat fragmentation on domatia-dwelling mites and a mite-plant-fungus tritrophic interaction

Abstract Context Habitat fragmentation is a leading threat to biodiversity, yet the impacts of fragmentation on most taxa, let alone interactions among those taxa, remain largely unknown. Objectives We studied how three consequences of fragmentation—reduced patch connectivity, altered patch shape, and edge proximity—impact plant-dwelling mite communities and mite-plant-fungus interactions within a large-scale habitat fragmentation experiment. Methods We sampled mite communities from the leaves of Quercus nigra (a plant species that has foliar domatia which harbor fungivorous and predacious mites) near and far from edge within fragments of varying edge-to-area ratio (shape) and connectivity via corridors. We also performed a mite-exclusion experiment across these fragmentation treatments to test the effects of mite presence and fungal hyphal abundance on leaf surfaces. Results Habitat edges influenced the abundance and richness of leaf-dwelling mites; plants closer to the edge had higher mite abundance and species richness. Likewise, hyphal counts were higher on leaves near patch edges. Despite both mite and fungal abundance being higher at patch edges, leaf hyphal counts were not impacted by mite abundance on those leaves. Neither patch shape nor connectivity influenced mite abundance, mite species richness, or the influence of mites on leaf surface fungal abundance. Conclusion Our results suggest that mites and foliar fungi may be independently affected by edge-structured environmental gradients, like temperature, rather than trophic effects. We demonstrate that large-scale habitat fragmentation and particularly edge effects can have impacts on multiple levels of microscopic communities, even in the absence of cascading trophic effects.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

The influence of alloying on slip intermittency and the implications for dwell fatigue in titanium

Dwell fatigue, the reduction in fatigue life experienced by titanium alloys due to holds at stresses as low as 60% of yield, has been implicated in several uncontained jet engine failures. Dislocation slip has long been observed to be an intermittent, scale-bridging phenomenon, similar to that seen in earthquakes but at the nanoscale, leading to the speculation that large stress bursts might promote the initial opening of a crack. Here we observe such stress bursts at the scale of individual grains in situ, using high energy X-ray diffraction microscopy in Ti–7Al–O alloys. This shows that the detrimental effect of precipitation of ordered Ti 3 Al is to increase the magnitude of rare pri $\langle$a$\rangle$ and bas $\langle$a$\rangle$ slip bursts associated with slip localisation. By contrast, the addition of trace O interstitials is beneficial, reducing the magnitude of slip bursts and promoting a higher frequency of smaller events. This is further evidence that the formation of long paths for easy basal plane slip localisation should be avoided when engineering titanium alloys against dwell fatigue.

36 MATERIALS SCIENCE↗
DOE OSTI2024

On the Impact of Bus Dwelling on Macroscopic Fundamental Diagrams

Network macroscopic fundamental diagrams (MFDs) have recently been shown to exist in real-world urban traffic networks. When present, MFDs can be used to model traffic dynamics within an urban network by dividing the network into a set of spatially compact homogeneous regions and tracking the average level of congestion in each region. Existing analytical methods to estimate MFD mostly focus on the behavior of a single type of vehicle and do not capture the patterns of mixed traffic (e.g., cars and buses). The existence of buses matters since a bus will block the movements of other vehicles when it dwells at the bus stop. This paper proposes an analytical method to estimate the impact of bus dwelling on a network’s MFD based on the network’s geometric features, traffic control strategies, and bus operation parameters, and validates the performance of the proposed method using simulations based on microscopic traffic models. Comparisons of the analytical and simulation results show that the proposed analytical method can generally provide a good estimate of the lower bound and upper bound of the network’s MFD.

Xu, Guanhao↗
DOE OSTI2022

Home charging for all: Techno-economic and life cycle assessment of multi-unit dwelling electric vehicle charging hubs

Ubiquitous electric vehicle adoption can drastically reduce greenhouse gas emissions (GHG) but will require equitable home charging infrastructure for all residences. Unlike single-family homes, Multi-Unit Dwellings (MUD) currently lack market share and access to nearby charging infrastructure partly due to expensive capital costs for reluctant residential property-owners. Further, this work evaluates the levelized cost of charging (LCOC) for Battery Electric Vehicles (BEVs) at MUD community charging hubs through a techno-economic analysis (TEA) that leverages real-world charging data and costs. Three different MUD charging types are investigated for a baseline and optimistic case: 1.9-kW Level 1 (L1), 6.6-kW Level 2 (L2), and 50-kW Direct Current Fast Charging (DCFC) stations under three different ownership models: resident, utility, and private company. Results demonstrate L1 and L2 chargers to be less expensive than the gasoline equivalent across the United States. Further, utility and private company ownership models, which avoid initial costs for residential property owners, result in a large LCOC premium for L1 and moderate LCOC premium for L2 relative to the resident ownership model. In contrast, DCFC is shown to be expensive for baseline scenarios but economical for optimistic scenarios especially under private company ownership. This work also performs a cradle to grave (C2G) life cycle assessment (LCA) of an average passenger BEV and gasoline conventional vehicle (CV) using yearly (grid mix & vehicle parameters), hourly (grid mix), and state-level (grid mix) resolution. Results show BEVs to have lower GHG emissions (-86% to-10%) than gasoline CVs in the contiguous U.S. Next, the system boundary of the TEA is extended to the total cost of ownership (TCO) of BEVs. The TCO is then coupled with the C2G GHG emissions to calculate the cost of GHG emissions reduction. Ultimately, the cost of GHG emissions reduction from MUD BEVs relative to gasoline CVs is shown to be negative for every scenario except baseline DCFC, meaning MUD BEV charging infrastructure can be a cost-effective endeavor to reduce GHG emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Revenue-Maximizing Shared Parking and Electric Vehicle Charging Management in Multi-Unit Dwellings

In urban areas, searching for parking and electric vehicle (EV) charging can result in cruising, congestion, and environmental externalities. Recognizing the business opportunity of offering private parking and charging infrastructure access within multi-unit dwellings (MUDs) during daytime, we model a shared parking and EV charging management system. We maximize the revenue of MUD charging hubs in mixed land use, catering to public demand. Our approach accounts for the objectives of the two stakeholders involved: a demand model is fitted on the choices of EV charging users, and the supply model optimizes the allocation of parking and charging requests in an MUD parking lot. A binary integer linear programming model for the allocation of parking and charging spaces with a rolling horizon is integrated with matching rules that handle both parking and charging requests. In our numerical experiments in a neighborhood of Chicago, Illinois, we estimate the performance of the MUD parking and charging system with metrics that include revenue, number of matchings, and utilization rates. At any given time, MUDs with lower prices attract more charging requests, particularly those of longer duration, resulting in higher revenue and greater charging utilization. Dynamic pricing facilitates a more equitable distribution of requests; as MUD parking lots reach capacity and their fees increase, other MUDs become more competitive, attracting additional requests. Comparing our method against first-come-first-served and optimal-solution benchmarks, we demonstrate our model’s effectiveness in dynamically managing mixed parking and charging demand in MUD charging hubs.

electric vehicle, multi-unit dwelling, charging in↗
DOE OSTI2020

Comparison of carrier localization effects between InAs quantum dashes and quantum dots in a DWELL (dashes- or dots-in-a-well) configuration

The optical properties of InAs quantum dashes (QDashes) grown on InP and InAs quantum dots (QDots) grown on GaAs in a dashes- or dots-in-a-well (DWELL) configuration are comparatively investigated using temperature-dependent photoluminescence (PL) measurements. The trends in PL characteristics such as exciton energy, spectral bandwidth and integrated intensity with respect to temperature are found to be distinctly dissimilar between the two systems. A rate-equation model involving exciton recombination and thermal transfer in a localized-state ensemble is used to quantitively interpret the experimental data. The results of this study suggest that QDashes in this configuration exhibit PL properties more consistent with a lower degree of carrier localization compared to QDots. A preliminary structural analysis highlighting the shape/size differences between the two nanostructures is also presented.

carrier localization↗
DOE OSTI2024

Xylem-dwelling pathogen unaffected by local xylem vessel network properties in grapevines ( Vitis spp.)

Abstract Background and aims Xylella fastidiosa (Xf) is the xylem-dwelling bacterium associated with Pierce’s disease (PD), which causes mortality in agriculturally important species, such as grapevine (Vitis vinifera). The development of PD symptoms in grapevines depends on the ability of Xf to produce cell-wall-degrading enzymes to break up intervessel pit membranes and systematically spread through the xylem vessel network. Our objective here was to investigate whether PD resistance could be mechanistically linked to xylem vessel network local connectivity. Methods We used high-resolution X-ray micro-computed tomography (microCT) imaging to identify and describe the type, area and spatial distribution of intervessel connections for six different grapevine genotypes from three genetic backgrounds, with varying resistance to PD (four PD resistant and two PD susceptible). Key results Our results suggest that PD resistance is unlikely to derive from local xylem network connectivity. The intervessel pit area (Ai) varied from 0.07 ± 0.01 mm2 mm−3 in Lenoir to 0.17 ± 0.03 mm2 mm−3 in Blanc do Bois, both PD resistant. Intervessel contact fraction (Cp) was not statically significant, but the two PD-susceptible genotypes, Syrah (0.056 ± 0.015) and Chardonnay (0.041 ± 0.013), were among the most highly connected vessel networks. Neither Ai nor Cp explained differences in PD resistance among the six genotypes. Bayesian re-analysis of our data shows moderate evidence against the effects of the traits analysed: Ai (BF01 = 4.88), mean vessel density (4.86), relay diameter (4.30), relay density (3.31) and solitary vessel proportion (3.19). Conclusions Our results show that radial and tangential xylem network connectivity is highly conserved within the six different Vitis genotypes we sampled. The way that Xf traverses the vessel network may limit the importance of local network properties to its spread and may confer greater importance on host biochemical responses.

Plant Sciences↗
DOE OSTI2021

LightMAT - Continuous fiber malleable thermoset composites with sub-1-minute dwell times; validation of impact performance and evaluation of the efficacy of the compression forming process (CRADA 409 Final Report)

In spite of carbon fiber composite materials’ significant impact on light-weighting, performance, and efficiency in the aerospace industry, adoption of these materials has been slow in high-volume industries such as automotive. Two major barriers to adoption are cost and cycle-time. Current approaches to thermoset composite part production are dependent on in-mold curing of thermosets which are not optimal for high volume, high throughput production due to limitations and inefficiencies associated with the in-mold cure itself. In addition, ancillary activities, such as transport and storage of shelf-life-limited uncured, or B-staged prepreg materials typically necessitate refrigerated transport and storage which significantly impacts the economic and energy costs associated with manufacturing. Furthermore, limited out-life means that trimmings cannot typically be used as they partially cure during initial production leading to high scrap rates (+20% is common). Finally, the need to cure in-mold drives cycle times to multiple minutes in the best cases, and 10’s of minutes to hours in most cases. Mallinda is developing polyimine malleable thermoset prepreg composite materials which have excellent mechanical properties (100 GPa tensile modulus, 2 GPA tensile strength, 2.4% elongation at break) and high operating temperatures (Tg>200°C). At scale, polyimine resins are commensurate in price with commodity epoxy resins. What distinguishes malleable thermoset prepreg from traditional thermoset prepreg materials, is that they are fully cured during Mallinda’s roll-to-roll production of prepreg laminate. This results in 5 key value-differentiating benefits. First, it simplifies manufacturing logistics by enabling ambient transportation and storage, and by significantly extending out-life and shelf-life almost indefinitely. Second, elimination of autoclave curing reduces the economic and energy costs to the customer. Third, scrap rates can be reduced as malleable thermoset prepreg materials are directly reusable. Fourth, the manufacturing consolidation step can be roughly 10x faster than traditional thermosets, because the resin is already cured. Parts can be made via compression forming by the application of heat and pressure to quickly vitrify and consolidate a multilayer part – easily leading to sub 3-minute cycle times (at lab scale we have demonstrated a 20 second dwell time, with room for further optimization). Finally, the closed-loop cradle-to-cradle solution-based recyclability of malleable thermoset composites can also contribute significantly to the future of sustainable lightweight materials. The focus of this project was the development, optimization and validation of malleable thermoset composite materials which exhibit manufacturing cycle times of 3-minute or less, high speed impact performance on par with incumbent technologies, and defect-free consolidation of 3 dimensional parts. Government funding is required on this project because Mallinda is a start-up company whose focus is the development and scale-up of the described technology for introduction to the transportation segment. Unlike incumbent industry players, Mallinda is bringing a completely new and highly relevant malleable thermoset technology to bear on the problem of high throughput composites. As a small business, Mallinda relies on a combination of government R&D funding and private capital to perform development work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Continuous fiber malleable thermoset composites with sub-1-minute dwell times; validation of impact performance and evaluation of the efficacy of the compression forming process. CRADA Final Report

Mallinda is developing polyimine malleable thermoset prepreg composite materials which have excellent mechanical properties (100 GPa tensile modulus, 2 GPA tensile strength, 2.4% elongation at break) and high operating temperatures (Tg>200°C). At scale, polyimine resins are commensurate in price with commodity epoxy resins. What distinguishes malleable thermoset prepreg from traditional thermoset prepreg materials, is that they are fully cured during Mallinda’s roll-to-roll production of prepreg laminate. This results in 5 key value-differentiating benefits. First, it simplifies manufacturing logistics by enabling ambient transportation and storage, and by significantly extending out-life and shelf-life almost indefinitely. Second, elimination of autoclave curing reduces the economic and energy costs to the customer. Third, scrap rates can be reduced as malleable thermoset prepreg materials are directly reusable. Fourth, the manufacturing consolidation step can be roughly 10x faster than traditional thermosets, because the resin is already cured. Parts can be made via compression forming by the application of heat and pressure to quickly vitrify and consolidate a multilayer part – easily leading to sub 3-minute cycle times (at lab scale we have demonstrated a 20 second dwell time, with room for further optimization). Finally, the closed-loop cradle-to-cradle solution-based recyclability of malleable thermoset composites can also contribute significantly to the future of sustainable lightweight materials. The focus of this project was the development, optimization and validation of malleable thermoset composite materials which exhibit manufacturing cycle times of 3-minute or less, high speed impact performance on par with incumbent technologies, and defect-free consolidation of 3 dimensional parts.

36 MATERIALS SCIENCE↗